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ABB ACS800-U4 Hardware Manual
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ABB ACS800-U4 Hardware Manual

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ACS800
Hardware Manual
ACS800-04 Drive Modules (0.55 to 200 kW)
ACS800-U4 Drive Modules (0.75 to 200 HP)
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com

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  • Page 1 ACS800 Hardware Manual ACS800-04 Drive Modules (0.55 to 200 kW) ACS800-U4 Drive Modules (0.75 to 200 HP) Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 2 ACS800 Single Drive Manuals HARDWARE MANUALS (appropriate manual is included in the delivery) ACS800-01/U1 Hardware Manual 0.55 to 200 kW (0.75 to 200 HP) 3AFE64382101 (English) ACS800-01/U1/04 Marine Supplement 0.55 to 200 kW (0.75 to 200 HP) 3AFE64291275 (English) ACS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP) 3AFE68367883 (English) ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP) 3AFE68599954 (English)
  • Page 3 ACS800-04 Drive Modules 0.55 to 200 kW ACS800-U4 Drive Modules 0.75 to 200 HP Hardware Manual 3AFE68372984 Rev E EN EFFECTIVE: 31.03.2008 © 2008 ABB Oy. All Rights Reserved. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 5 Update Notice The notice concerns the following ACS800-04 Drive Code: 3AUA0000068979 Rev B Modules (0.55 to 200 kW) and ACS800-U4 Drive Modules Valid: from 01.09.2010 until the release of the next revision of (0.75 to 200 HP) Hardware Manuals: the manual...
  • Page 6 Note: If you add or modify the wiring in the drive safety circuits, ensure that the appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and the ABB guidelines are met. After making the changes, verify the operation of the safety function by testing it.
  • Page 7 Update Notice Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 8 Note: If you add or modify the wiring in the drive safety circuits, ensure that the appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and the ABB guidelines are met. After making the changes, verify the operation of the safety function by testing it.
  • Page 9 Connect the optional ASTO board as follows: • Remove the cover of the enclosed ASTO unit by undoing the fixing screws (1). • Ground the ASTO unit via the bottom plate of the enclosure or via terminal X1:2 or X1:4 of the ASTO board. •...

  • Page 10: Acs800 Single Drive Manuals

    The diagram below shows the connection between the ASTO board and the drive when it is ready. For an example diagram of a complete Safe torque off circuit, see page 3 (in this Update Notice). 3AUA0000069101 NEW (page 84): Installation check-list The following step has been added to the ELECTRICAL INSTALLATION procedure: Modules with the Safe torque off option (+967) only (ASTO board): The Safe torque off circuit is completed and the supply voltage for ASTO-11C board is 24 V.
  • Page 11 NEW (page 109): ASTO-11C Nominal input voltage 24 V DC Nominal input current 40 mA (20mA per channel) X1 terminal sizes 4 x 2.5 mm Nominal output current 0.4 A X2 terminal block type JST B4P-VH Ambient temperature 0...50°C Relative humidity Max.
  • Page 12 Update Notice Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 13: Safety Instructions

    Safety instructions What this chapter contains This chapter contains the safety instructions which you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read the safety instructions before you work on the unit.

  • Page 14: Installation And Maintenance Work

    Installation and maintenance work These warnings are intended for all who work on the drive, motor cable or motor. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • Only qualified electricians are allowed to install and maintain the drive. •...

  • Page 15: Grounding

    Grounding These instructions are intended for all who are responsible for the grounding of the drive. WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction: • Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and interference.

  • Page 16: Mechanical Installation And Maintenance

    Mechanical installation and maintenance These instructions are intended for all who install and service the drive. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • Handle the unit carefully. • The drive is heavy. Do not lift it alone. Place the unit only on its back. •...

  • Page 17: Operation

    Operation These warnings are intended for all who plan the operation of the drive or operate the drive. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive.

  • Page 18: Permanent Magnet Motor

    Permanent magnet motor These are additional warnings concerning permanent magnet motor drives. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Installation and maintenance work WARNING! Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.

  • Page 19: Table Of Contents

    Providing feedback on ABB Drives manuals ........
  • Page 20 What this chapter contains ............27 Cabinet construction .
  • Page 21 Motor cable shield ............52 Additional US requirements .
  • Page 22 Motor control and I/O board (RMIO) What this chapter contains ............77 Note on terminal labelling .
  • Page 23 Altitude derating ............94 Cooling characteristics .
  • Page 24 Dimensional drawings What this chapter contains ............117 Frame size R2 (with optional control panel) .

  • Page 25: About This Manual

    About this manual What this chapter contains This chapter describes the intended audience and contents of this manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.

  • Page 26: Contents

    Contents The chapters of this manual are briefly described below. Safety instructions give safety instructions for the installation, commissioning, operation and maintenance of the drive. About this manual lists the steps in checking the delivery and installing and commissioning the drive and refers to chapters/sections in this manual and other manuals for particular tasks.

  • Page 27: Installation And Commissioning Flowchart

    If the converter has been non-operational for equipment are present and correct. more than one year, the converter DC link capacitors need to be reformed. Ask ABB for Only intact units may be started up. instructions. Check the installation site.

  • Page 28: Product And Service Inquiries

    Address any inquiries about the product to your local ABB representative, quoting the type code and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to ABB website and selecting Drives –...

  • Page 29: Terms And Abbreviations

    CDP312R Drive control panel DDCS Distributed Drives Communication System; a protocol used in optical fibre communication inside and between ABB drives. Electromagnetic Compatibility Frame (size) Size of the frame into which the drive module is assembled. Several supply modules with different nominal powers may have the same frame size.
  • Page 30 About this manual Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 31: Acs800-04/U4

    ACS800-04/U4 What this chapter contains This chapter describes the operating principle and construction of the drive in short. Layout The ACS800-04/U4 (frame sizes R2 to R6) is an IP20 drive module for controlling AC motors. It is to be installed into a cabinet by the customer with wall fastening. Frame size R2 Control panel CDP312R (optional)

  • Page 32: Type Code

    Type code The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. ACS800-04- 0016-3). The optional selections are given thereafter, separated by + signs (e.g. +E202). The main selections are described below. Not all selections are available for all types.

  • Page 33: Main Circuit And Control

    Main circuit and control Diagram This diagram shows the control interfaces and the main circuit of the drive. Location of terminals vary depending on the drive frame size. Drive Optional module 1: RMBA, RAIO, RDIO, Slot1 Motor RDNA, RLON, RIBA, RPBA, RCAN, RCNA, control and RMBP, RETA, RRIA or RTAC I/O board...

  • Page 34: Operation

    Operation This table describes the operation of the main circuit in short. Component Description Six-pulse rectifier Converts the three-phase AC voltage to DC voltage. Capacitor bank Energy storage which stabilizes the intermediate circuit DC voltage. IGBT inverter Converts the DC voltage to AC voltage and vice versa. The motor operation is controlled by switching the IGBTs.

  • Page 35: Planning The Cabinet Assembly

    Note: The installation examples in this manual are provided only to help the installer in designing the installation. The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations.

  • Page 36: Free Space Around The Unit

    Free space around the unit The modules can be installed side by side. Recommended free space above and below the drive to enable cooling air flow, service and maintenance is shown below in millimetres and [inches]. The temperature of the cooling air entering the unit must not exceed the maximum allowed ambient temperature.

  • Page 37: Cooling And Degrees Of Protection

    Cooling and degrees of protection The cabinet must have enough free space for the components to ensure sufficient cooling. Observe the minimum clearances given for each component. The air inlets and outlets must be equipped with gratings that • guide the air flow •...

  • Page 38: Preventing The Recirculation Of Hot Air

    In IP54 (UL type 12) cabinets, thick filter mats are used to prevent water splashes from entering the cabinet. This entails the installation of additional cooling equipment, such as a hot air exhaust fan. The installation site must be sufficiently ventilated. Preventing the recirculation of hot air Normal vertical mounting Flange mounting...

  • Page 39: Inside The Cabinet

    Inside the cabinet Prevent hot air circulation inside the cabinet with leak-proof air baffle plates. No gaskets are usually required. When several modules are installed vertically in one cabinet, the hot air from one module must not be allowed to enter another module. In a cabinet with multiple modules, a practical way of achieving this is to install a mounting plate to separate the cool area (at the front part of the cabinet) from the hot area (back part).

  • Page 40: Cabinet Heaters

    Cabinet heaters Use a cabinet heater if there is a risk of condensation in the cabinet. Although the primary function of the heater is to keep the air dry, it may also be required for heating at low temperatures. When placing the heater, follow the instructions provided by its manufacturer.

  • Page 41: Control Panel Mounting Platform Kit (Rpmp)

    Control panel mounting platform kit (RPMP) For installation of the mounting platform, see Control Panel Mounting Platform Kit (RPMP) Installation Guide [3AFE64677560 (English)]. EMC requirements Generally, the fewer and smaller the holes in the cabinet, the better the interference attenuation. The maximum recommended diameter of a hole in galvanic metal contact in the covering cabinet structure is 100 mm.
  • Page 42 360° high frequency grounding of the control cable shields is recommended at their entries. The shields can be grounded by means of conductive shielding cushions pressed against the cable shield from both directions: Bare cable shield Shielding cushion (conductive) Cabinet bottom plate Cable Cable grommet Planning the cabinet assembly...

  • Page 43: Mechanical Installation

    Mechanical installation Unpacking the unit The drive is delivered in a box that also contains: • plastic bag containing: screws (M3), clamps and cable lugs (2 mm , M3) for grounding the control cable screens • residual voltage warning stickers •...

  • Page 44: Delivery Check

    Delivery check Check that there are no signs of damage. Before attempting installation and operation, check the information on the type designation label of the drive to verify that the unit is of the correct type. The label includes IEC rating, C-UL US, CSA, C-tick and CE markings, a type code and a serial number, which allow individual recognition of each unit.

  • Page 45: Installation Procedure

    Installation procedure 1. Mark the locations for the four holes. The mounting points are shown in Dimensional drawings. With frame sizes R2...R5, use the mounting template cut from the package. 2. Fix the screws or bolts to the marked locations. 3.

  • Page 46: Flange Mounting

    Flange mounting The flange mounting plate is factory assembled on the drive. With flange mounting, the degree of protection is IP55 for the heat sink side and IP20 for the drive front side. The drive front side must always be housed in a cabinet. R6 with flange mounting plate Connect a drive with flange mounting plate as follows: 1.
  • Page 47 R6 flange mounting Lifting lug Mounting plate Washer Screw Mechanical installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 48 Mechanical installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 49: Planning The Electrical Installation

    Note: The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 50: Protecting The Motor Insulation And Bearings

    The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/dt filters also reduce bearing currents.

  • Page 51: Requirements Table

    Requirements table The following table shows how to select the motor insulation system and when an optional ABB du/dt filter, insulated N-end (non-driven end) motor bearings and ABB common mode filters are required. The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (Ex) motors.
  • Page 52 Motor type Nominal mains Requirement for voltage (AC line Motor ABB du/dt filter, insulated N-end bearing and ABB common voltage) insulation mode filter system < 100 kW 100 kW < P < > 350 kW 350 kW or frame size > IEC frame size <...
  • Page 53 For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001) and for IP23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are given below. For other motor types, see the Requirements table above. Apply the requirements of range 100 kW <...

  • Page 54: Permanent Magnet Synchronous Motor

    Note 7: Calculating the rise time and the peak line-to-line voltage The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length. The requirements for the motor insulation system given in the table are “worst case”...

  • Page 55: Eea / Europe

    EEA / Europe If the drive is used in an application which must meet the European Union Machinery Directive according to standard EN 60204-1 Safety of Machinery, the disconnecting device must be one of the following types: • a switch-disconnector of utilization category AC-23B (EN 60947-3) •...

  • Page 56: Thermal Overload Protection Of The Motor

    Thermal overload protection of the motor According to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary.

  • Page 57: Ground Fault Protection

    2) Circuit breakers which have been tested by ABB with the ACS800 can be used. Fuses must be used with other circuit breakers. Contact your local ABB representative for approved breaker types and supply network characteristics. The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers.

  • Page 58: Prevention Of Unexpected Start

    EN 60204-1: 1997. • indicating lamp; on = starting the drive is prevented, off = drive is operative. • safety relay (type BD5935 has been approved by ABB) (Switching/disconnecting device, indicating lamp and safety relay are not included in the delivery.)

  • Page 59: Selecting The Power Cables

    Selecting the power cables General rules Dimension the mains (input power) and motor cables according to local regulations: • The cable must be able to carry the drive load current. See chapter Technical data for the rated currents. ° • The cable must be rated for at least 70 C maximum permissible temperature of conductor in continuous use.

  • Page 60: Alternative Power Cable Types

    Alternative power cable types Power cable types that can be used with the drive are represented below. Recommended Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity and a concentric or otherwise symmetrically of the cable shield is < 50% of the conductivity of the constructed PE conductor, and a shield phase conductor.

  • Page 61: Additional Us Requirements

    Additional US requirements Type MC continuous corrugated aluminium armor cable with symmetrical grounds or shielded power cable must be used for the motor cables if metallic conduit is not used. For the North American market, 600 V AC cable is accepted for up to 500 V AC.

  • Page 62: Power Factor Compensation Capacitors

    Power factor compensation capacitors Power factor compensation is not needed with AC drives. However, if a drive is to be connected in a system with compensation capacitors installed, note the following restrictions. WARNING! Do not connect power factor compensation capacitors or harmonic filters to the motor cables (between the drive and the motor).

  • Page 63: Before Opening A Contactor (Dtc Control Mode Selected)

    Before opening a contactor (DTC control mode selected) Stop the drive and wait for the motor to stop before opening a contactor between the output of the drive and the motor when the DTC control mode is selected. See the appropriate ACS800 Control Program Firmware Manual for the required parameter settings.

  • Page 64: Selecting The Control Cables

    Control panel cable In remote use, the cable connecting the control panel to the drive must not exceed 3 metres (10 ft). The cable type tested and approved by ABB is used in control panel option kits. Planning the electrical installation...

  • Page 65: Connection Of A Motor Temperature Sensor To The Drive I/O

    Connection of a motor temperature sensor to the drive I/O WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non- conductive or conductive but not connected to the protective earth. To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital inputs of the drive can be implemented in three alternate ways:...

  • Page 66: Control Cable Ducts

    A diagram of the cable routing is below. Motor cable Drive min 300 mm (12 in.) Power cable Input power cable Motor cable 90° min 200 mm (8 in.) min 500 mm (20 in.) Control cables Control cable ducts 230 V 230 V (120 V) (120 V)

  • Page 67: Electrical Installation

    Electrical installation What this chapter contains This chapter describes the electrical installation procedure of the drive. WARNING! The work described in this chapter may only be carried out by a qualified electrician. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.

  • Page 68: It (Ungrounded) Systems

    +E202 and +E200 before connecting the drive to an ungrounded system. For detailed instructions on how to do this, please contact your local ABB distributor. WARNING! If a drive with EMC filter selection +E202 or +E200 is installed on an IT...

  • Page 69: Power Cable Connection

    Power cable connection Power cable connection Drive with brake chopper included OUTPUT INPUT UDC+ U2 V2 W2 V1 W1 (PE) (PE) External brake For alternatives, see resistor (360 Planning the electrical degrees grounding Motor installation: required) Disconnecting device (means). Connecting the power cables •...

  • Page 70: Grounding The Motor Cable Shield At The Motor End

    • Connect the phase conductors of the mains cable to the U1, V1 and W1 terminals and the phase conductors of the motor cable to the U2, V2 and W2 terminals. Strip the conductor ends as follows to fit them inside the power cable connection terminals.

  • Page 71: Frame Sizes R2 To R4

    Frame sizes R2 to R4 UDC+ R+ UDC Input power cable Motor cable Frame size R5 UDC+ U2 V2 W2 PE Motor cable Input power cable Electrical installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 72: Frame Size R6: Cable Lug Installation [16 To 70 Mm2 (6 To 2/0 Awg) Cables]

    Frame size R6: Cable lug installation [16 to 70 mm (6 to 2/0 AWG) cables] UDC+ Remove the screw terminals. R+ UDC- Fasten the cable lugs to the remaining bolts with M10 nuts. Isolate the ends of the cable lugs with insulating tape or shrink tube Input power cable Motor cable...

  • Page 73: Power Cable Protection

    Frame size R6: Cable terminal installation [95 to 185 mm (3/0 to 2×4/0 AWG) cables] UDC+ R+ UDC- a. Connect the cable to the terminal. b. Connect the terminal to the drive. WARNING! If the wire size is less than 95 mm (3/0 AWG), a cable lug must be used.

  • Page 74: Frame Size R6

    Removal of the shroud with a screw driver: Frame size R6 Cover the power cable terminals as follows: 1. Cut holes for the installed cables into the clear plastic shroud in cable lug installations. 2. Press the shroud onto the terminals. View of cable terminal installation Removal of the shroud by lifting up with a screw driver from the corner:...

  • Page 75: Connecting The Control Cables

    Connecting the control cables Connect the control cables as described below. Connect the conductors to the appropriate detachable terminals of the RMIO board [see chapter Motor control and I/O board (RMIO)]. Tighten the screws to secure the connection. Terminals Location of terminals vary depending on the drive frame size. Frame sizes R2 to R4 The control cable connection terminals are exposed when the control panel mounting platform...
  • Page 76 Frame sizes R5 and R6 View of frame size R6 X41 for Prevention of Control panel Unexpected Start (AGPS (optional) board) Optional module 1 Optional module 2 DDCS communication option module 3: RDCO Control cable grounding: see Place the warning sticker here section degrees Detachable connection terminals (pull up)

  • Page 77: Degrees Grounding

    360 degrees grounding Insulation Double-shielded cable Single-shielded cable When the outer surface of the shield is covered with non-conductive material • Strip the cable carefully (do not cut the grounding wire and the shield) • Turn the shield inside out to expose the conductive surface. •...

  • Page 78: Cabling Of I/O And Fieldbus Modules

    Cabling of I/O and fieldbus modules Module As short as possible Shield Note: The RDIO module does not include a terminal for cable shield grounding. Ground the pair cable shields here. Pulse encoder module cabling As short as possible Note1: If the encoder is of unisolated type, ground the encoder cable at the drive end only.

  • Page 79: Installation Of Optional Modules And Pc

    Installation of optional modules and PC The optional module (such as fieldbus adapter, I/O extension module and the pulse encoder interface) is inserted in the optional module slot of the RMIO board (see section Connecting the control cables) and fixed with two screws. See the appropriate optional module manual for cable connections.
  • Page 80 Frame sizes R2 to R4 Frame sizes R5 and R6 Electrical installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 81 RMIO board RMIO board Connection of a two-way Connection of a three-way connector connector Electrical installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 82: Prevention Of Unexpected Start, Agps Board

    Prevention of Unexpected Start, AGPS board WARNING! Dangerous voltages can be present on the AGPS board even when the 115...230 V supply is switched off. Follow the Safety instructions on the first pages of this manual and the instruction in this section when working on the AGPS board. Make sure that the drive is disconnected from the mains (input power) and the 115...230 V source for the AGPS board is switched off during installation and maintenance.
  • Page 83 Note: Location of the X41 terminal block varies according to the drive frame size, see page 67. Note: Maximum cable length between AGPS terminal block X2 and drive terminal block is restricted to 10 m. For technical data see section AGPS-11C in chapter Technical...
  • Page 84 The following figure presents the circuit diagram of the Prevention of Unexpected Start. Electrical installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 85: Motor Control And I/O Board (Rmio)

    Motor control and I/O board (RMIO) What this chapter contains This chapter shows • external control connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro) • specifications of the inputs and outputs of the board. This chapter applies to ACS800 units which employ RMIO-01 board from revision J onwards and RMIO-02 board from revision H onwards.

  • Page 86: External Control Connections (Non-Us)

    External control connections (non-US) External control cable connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro) are shown below. For external control connections of other control macros and programs, see the appropriate Firmware Manual. Terminal block size: VREF- Reference voltage -10 V DC, 1 kohm <...

  • Page 87: External Control Connections (Us)

    External control connections (US) External control cable connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro US version) are shown below. For external control connections of other control macros and programs, see the appropriate Firmware Manual. Terminal block size: VREF- Reference voltage -10 V DC, 1 kohm <...

  • Page 88: Rmio Board Specifications

    RMIO board specifications Analogue inputs With Standard Control Program two programmable differential current inputs (0 mA / 4 mA ... 20 mA, R = 100 ohm) and one programmable differential voltage input (- 10 V / 0 V / 2 V ... +10 V, R >...

  • Page 89: Relay Outputs

    Contact material Silver Cadmium Oxide (AgCdO) Insulation test voltage 4 kV AC, 1 minute DDCS fibre optic link With optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System) 24 V DC power input Voltage 24 V DC ±10%...
  • Page 90 Isolation and grounding diagram (Test voltage: 500 V AC) VREF- AGND VREF+ AGND AI1+ Common mode AI1- voltage between AI2+ channels ±15 V AI2- AI3+ AI3- AO1+ AO1- AO2+ AO2- Jumper J1 settings: DGND1 All digital inputs share a common ground. This is the default setting.

  • Page 91: Installation Checklist

    Installation checklist Checklist Check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. Read the Safety instructions on the first pages of this manual before you work on the unit. Check MECHANICAL INSTALLATION The ambient operating conditions are allowed.
  • Page 92 Check Modules with prevention of unexpected start option only (AGPS board): The prevention of unexpected start circuit is completed. Installation checklist Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 93: Maintenance

    Ignoring the safety instructions can cause injury or death. Maintenance intervals If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB. Maintenance Interval Instruction...

  • Page 94: Fan

    If the drive is operated in a critical part of a process, fan replacement is recommended once these symptoms start appearing. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

  • Page 95: Fan Replacement (R4)

    Fan replacement (R4) 1. Loosen the screws that fasten the fan mounting plate to the frame. 2. Push the fan mounting plate to the left and pull it out. 3. Disconnect the fan power cable. 4. Undo the screws that fasten the fan to the fan mounting plate. 5.

  • Page 96: Fan Replacement (R5)

    Fan replacement (R5) 1. Undo the fastening screws of the swing-out frame. 2. Open the swing-out frame. 3. Disconnect the cable. 4. Undo the fastening screws of the fan. 5. Install the new fan in reverse order. Bottom view Maintenance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 97: Fan Replacement (R6)

    Fan replacement (R6) To remove the fan, undo the fixing screws. Disconnect the cable. Install the new fan in reverse order. Bottom view Additional fan In ACS800-04/U4 (R2...R6) units there is an additional fan in all types except in -0001-2, -0002-2, -0003-2, -0003-3, -0004-3, -0005-3, -0004-5, -0005-5 and -0006-5.

  • Page 98: Replacement (R4, R5)

    It is not possible to predict a capacitor failure. Capacitor failure is usually followed by a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected. Replacements for frame size R4 and up are available from ABB. Do not use other than ABB specified spare parts.

  • Page 99: Technical Data

    Technical data What this chapter contains This chapter contains the technical specifications of the drive, e.g. the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings and warranty policy. IEC data Ratings The IEC ratings for the ACS800-04 with 50 Hz and 60 Hz supplies are given below. The symbols are described below the table.
  • Page 100 ACS800-04 size Nominal No-overload Light-overload Heavy-duty use Frame Heat ratings size flow dissipation cont.max cont.max Three-phase supply voltage 380 V, 400 V or 415 V -0003-3 -0004-3 -0005-3 10.8 -0006-3 10.9 13.8 10.2 -0009-3 13.9 17.6 12.7 -0011-3 -0016-3 -0020-3 -0023-3 18.5 -0025-3...

  • Page 101: Symbols

    ACS800-04 size Nominal No-overload Light-overload Heavy-duty use Frame Heat ratings size flow dissipation cont.max cont.max Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V -0011-7 11.5 -0016-7 -0020-7 18.5 -0025-7 18.5 -0030-7 18.5 -0040-7 -0050-7 -0060-7...

  • Page 102: Derating

    Derating The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres (3300 ft), or if the ambient temperature exceeds 40 °C (104 °F). Temperature derating In the temperature range +40 °C (+104 °F) to +50 °C (+122 °F) the rated output current is decreased by 1% for every additional 1 °C (1.8 °F).

  • Page 103: Fuses

    ACS800-04 Input Fuse size current Manufacturer Type IEC size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0001-2 ABB Control OFAF000H10 -0002-2 ABB Control OFAF000H10 -0003-2 ABB Control OFAF000H10 -0004-2 ABB Control OFAF000H16...

  • Page 104: Frame Sizes R5 And R6

    Input Fuse size current Manufacturer Type IEC size Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V -0004-5 ABB Control OFAF000H10 -0005-5 ABB Control OFAF000H10 -0006-5 ABB Control OFAF000H10 -0009-5 10.0...

  • Page 105: Calculation Example

    2 · The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF00H160 (2400 A). -> The 500 V gG fuse (ABB Control OFAF00H160) can be used. Technical data Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 106: Gg Fuses

    Min. short- Fuse current circuit current Manufacturer Type IEC size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0025-2 1050 34500 ABB Control OFAF000H80 -0030-2 1480 63600 ABB Control OFAF000H100 -0040-2 1940 103000 ABB Control OFAF00H125...

  • Page 107: Ultrarapid (Ar) Fuses

    Ultrarapid (aR) fuses ACS800-04 size Input Min. Fuse current short- circuit current Manufacturer Type IEC size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0025-2 4650 Bussmann 170M1567 DIN000 -0030-2 8500 Bussmann 170M1568 DIN000 -0040-2 8500 Bussmann 170M1569 DIN000...

  • Page 108: Quick Guide For Selecting Between Gg And Ar Fuses

    Quick guide for selecting between gG and aR fuses The table below is a short cut in selecting between gG and aR fuses. The combinations (cable size, cable length, transformer size and fuse type) in the table fulfil the minimum requirements for the proper operation of the fuse. ACS800-01 size Cable type Supply transformer minimum apparent power S...

  • Page 109: Cable Types

    Selection of smaller fuses improves the protection, but may also affect the fuse life time and lead to unnecessary operation of the fuses. In case of any uncertainty regarding the drive protection, please contact your local ABB. Cable types The table below gives copper and aluminium cable types for different load currents.

  • Page 110: Cable Entries

    Cable entries Brake resistor, mains and motor cable terminal sizes (per phase) and tightening torques are given below Frame U1, V1, W1, U2, V2, W2, R+, R Earthing PE size Maximum wire size Tightening torque Maximum wire size Tightening torque up to 16 * 1.2...1.5 up to 10...

  • Page 111: Nema Data

    NEMA data Ratings The NEMA ratings for the ACS800-U4 with 60 Hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 Hz supplies, see section data. ACS800-U4 size Normal use Heavy-duty use Frame...

  • Page 112: Symbols

    ACS800-U4 size Normal use Heavy-duty use Frame Air flow Heat size dissipation /min BTU/Hr Three-phase supply voltage 525 V, 575 V or 600 V -0011-7 11.5 1050 -0016-7 1200 -0020-7 15/20*** 15 15** 1550 -0025-7 20** 1850 -0030-7 25/30*** 25...

  • Page 113: Fuses

    Note 3: Larger fuses than the recommended ones must not be used. Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table. ACS800-U4 Frame size Input...

  • Page 114: Cable Types

    ACS800-U4 Frame size Input Fuse type current Manufacturer Type UL class Three-phase supply voltage 525 V, 575 V, 600 V -0011-7 Bussmann JJS-20 -0016-7 Bussmann JJS-20 -0020-7 Bussmann JJS-30 -0025-7 Bussmann JJS-30 -0030-7 Bussmann JJS-45 -0040-7 Bussmann JJS-45 -0050-7 Bussmann...

  • Page 115: Cable Entries

    Cable entries Brake resistor, input and motor cable (per phase) terminal sizes and tightening torques are given below Frame U1, V1, W1, U2, V2, W2, R+, R Earthing PE size Maximum wire size Tightening torque Maximum wire size Tightening torque lbf ft lbf ft up to 6 *...

  • Page 116: Motor Connection

    Motor connection Voltage (U 0 to U , 3-phase symmetrical, U at the field weakening point Frequency DTC mode: 0 to 3.2 · f . Maximum frequency 300 Hz. Nmains · f Nmotor Nmotor : frequency at field weakening point; U : mains (input power) voltage;...

  • Page 117: Agps-11C

    AGPS-11C Nominal input voltage 115...230 V AC ±10% Nominal input current 0.1 A (230 V) / 0.2 A (115 V) Nominal frequency 50/60 Hz Max. external fuse 16 A X1 terminal sizes 3 x 2.5 mm Output voltage 15 V DC ±0.5 V Nominal output current 0.4 A X2 terminal block type...

  • Page 118: Materials

    EU. They must be removed and handled according to local regulations. For further information on environmental aspects and more detailed recycling instructions, please contact your local ABB distributor. Applicable standards The drive complies with the following standards. The compliance with the European Low Voltage Directive is verified according to standards EN 61800-5-1 and EN 60204-1.

  • Page 119: Ce Marking

    CE marking A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/ EEC, as amended by 2004/108EC). Definitions EMC stands for Electromagnetic Compatibility.

  • Page 120: Second Environment (Drive Of Category C3)

    Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in the Hardware Manual. 4. The drive is installed according to the instructions given in the Hardware Manual.

  • Page 121: C-Tick" Marking

    “C-tick” marking “C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to each drive in order to verify compliance with the relevant standard (IEC 61800-3 (2004) – Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific test methods), mandated by the Trans-Tasman Electromagnetic Compatibility Scheme.

  • Page 122: Second Environment (Drive Of Category C3)

    Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in the Hardware Manual. 4. The drive is installed according to the instructions given in the Hardware Manual.

  • Page 123: Ul/Csa Markings

    If you have any questions concerning your ABB drive, please contact the local distributor or ABB office. The technical data, information and specifications are valid at the time of printing. The manufacturer reserves the right to modifications without prior notice.

  • Page 124: Product Protection In The Us

    Product protection in the US This product is protected by one or more of the following US patents: 4,920,306 5,301,085 5,463,302 5,521,483 5,532,568 5,589,754 5,612,604 5,654,624 5,799,805 5,940,286 5,942,874 5,952,613 6,094,364 6,147,887 6,175,256 6,184,740 6,195,274 6,229,356 6,252,436 6,265,724 6,305,464 6,313,599 6,316,896 6,335,607 6,370,049...

  • Page 125: Dimensional Drawings

    Dimensional drawings What this chapter contains Dimensional drawings of the ACS800-04/U4, flange mounting kits and AGPS board are shown below. The dimensions are given in millimetres and [inches]. Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 126: Frame Size R2 (With Optional Control Panel)

    Frame size R2 (with optional control panel) Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 127: Frame Size R3 (With Optional Control Panel)

    Frame size R3 (with optional control panel) Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 128: Frame Size R4 (With Optional Control Panel)

    Frame size R4 (with optional control panel) Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 129: Frame Size R5 (With Optional Control Panel)

    Frame size R5 (with optional control panel) Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 130: Frame Size R6 (With Optional Control Panel)

    Frame size R6 (with optional control panel) Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 131: Flange Mounting Kits

    Flange mounting kits Flange mounting kit dimensions: Lifting lug 7 [0.276] Frame size mm [in.] mm [in.] mm [in.] 476.5 [18.76] 235.5 [9.27] 25 [0.984] 530.5 [20.89] 245.5 [9.67] 25 [0.984] 595.95 [23.46] 373.6 [14.71] 25 [0.984] 700 [27.56] 398.8 [15.70] 25 [0.984] 786 [30.94] 433.4 [17.06]...

  • Page 132: Flange Mounting Kit For Frame Size R2

    Flange mounting kit for frame size R2 [0.276] [0.866] [7.54] [6.69] Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 133: Flange Mounting Kit For Frame Size R3

    Flange mounting kit for frame size R3 [7.09] [0.394] [0.276] [7.93] [0.866] Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 134: Flange Mounting Kit For Frame Size R4

    Flange mounting kit for frame size R4 86.8 [3.42] [12.40] [0.827] [0.276] [6.53] [3.94] Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 135: Flange Mounting Kit For Frame Size R5

    Flange mounting kit for frame size R5 [13.39] [14.33] [0.276] [3.15] 119.4 [4.70] Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 136: Flange Mounting Kit For Frame Size R6

    Flange mounting kit for frame size R6 [8.66] 16.7 [0.657] [15.75] [0.276] [3.94] 116.7 [4.59] [3.94] Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 137: Agps Board

    AGPS board $)( Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 138 Dimensional drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 139: Resistor Braking

    Resistor braking What this chapter contains This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. Availability of brake choppers and resistors Frame R2 and R3 drives and 690 V units of frame size R4 have a built-in brake chopper as standard equipment.

  • Page 140: Optional Brake Chopper And Resistor(S)

    Optional brake chopper and resistor(s) The nominal ratings for dimensioning the brake resistors are given below at an ambient temperature of 40°C (104°F). ACS800-04 type Braking power of the chopper and Brake resistor(s) ACS800-U4 type the drive Type brcont Rcont (kW)
  • Page 141 ACS800-04 type Braking power of the chopper and Brake resistor(s) ACS800-U4 type the drive Type brcont Rcont (kW) (ohm) (kJ) (kW) 400 V units -0003-3 SACE08RE44 -0004-3 SACE08RE44 -0005-3 SACE08RE44 -0006-3 SACE08RE44 -0009-3 SACE08RE44 -0011-3 SACE15RE22 -0016-3 SACE15RE22 -0020-3 SACE15RE22...

  • Page 142: Resistor Installation And Wiring

    ACS800-04 type Braking power of the chopper and Brake resistor(s) ACS800-U4 type the drive Type brcont Rcont (kW) (ohm) (kJ) (kW) 690 V units -0011-7 SACE08RE44 -0016-7 SACE08RE44 -0020-7 SACE08RE44 -0025-7 SACE08RE44 -0030-7 SACE15RE22 -0040-7 22 / 33 SACE15RE22 -0050-7...

  • Page 143: Protection Of Frame Sizes R2 To R5

    Below is a simple example wiring diagram. L1 L2 L3 Fuses ACS800 Thermal switch (stand- Θ ard in ABB resistors) Resistor braking Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 144: Protection Of Frame Size R6

    Note: If an external brake chopper (outside the drive module) is used, a main contactor is always required. A thermal switch (standard in ABB resistors) is required for safety reasons. The cable must be shielded and not longer than the resistor cable.

This manual is also suitable for:

Acs800-04Acs800

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